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JP3883929B2 - Thin film forming apparatus and thin film forming method - Google Patents

Thin film forming apparatus and thin film forming method Download PDF

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Publication number
JP3883929B2
JP3883929B2 JP2002228343A JP2002228343A JP3883929B2 JP 3883929 B2 JP3883929 B2 JP 3883929B2 JP 2002228343 A JP2002228343 A JP 2002228343A JP 2002228343 A JP2002228343 A JP 2002228343A JP 3883929 B2 JP3883929 B2 JP 3883929B2
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Prior art keywords
thin film
substrate
exhaust
film forming
forming chamber
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JP2003174022A (en
Inventor
勉 上山
出 井関
昇男 佐藤
克之 町田
億 久良木
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Screen Holdings Co Ltd
Nippon Telegraph and Telephone Corp
Dainippon Screen Manufacturing Co Ltd
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Screen Holdings Co Ltd
Nippon Telegraph and Telephone Corp
Dainippon Screen Manufacturing Co Ltd
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Priority to JP2002228343A priority Critical patent/JP3883929B2/en
Priority to TW091118871A priority patent/TW565891B/en
Priority to KR1020020052542A priority patent/KR100566790B1/en
Priority to US10/251,475 priority patent/US7017637B2/en
Publication of JP2003174022A publication Critical patent/JP2003174022A/en
Priority to US11/330,449 priority patent/US20060113021A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
    • H01L21/18—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic Table or AIIIBV compounds with or without impurities, e.g. doping materials
    • H01L21/30—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/67—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
    • H01L21/67005—Apparatus not specifically provided for elsewhere
    • H01L21/67011—Apparatus for manufacture or treatment
    • H01L21/67092—Apparatus for mechanical treatment
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/67—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
    • H01L21/67005—Apparatus not specifically provided for elsewhere
    • H01L21/67242—Apparatus for monitoring, sorting or marking
    • H01L21/67253—Process monitoring, e.g. flow or thickness monitoring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/28—Processes for applying liquids or other fluent materials performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
    • B05D1/286—Processes for applying liquids or other fluent materials performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers using a temporary backing to which the coating has been applied
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/12—Pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/60—In a particular environment
    • B32B2309/68—Vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00—Electrical equipment
    • B32B2457/14—Semiconductor wafers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • B32B37/025—Transfer laminating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0036—Heat treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B41/00—Arrangements for controlling or monitoring lamination processes; Safety arrangements

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  • Condensed Matter Physics & Semiconductors (AREA)
  • General Physics & Mathematics (AREA)
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  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Fluid Mechanics (AREA)
  • Physical Vapour Deposition (AREA)

Description

【０００１】
【発明の属する技術分野】
この発明は、薄膜形成室内で基板とシートフィルムとを相互に押し付けることによりシートフィルムに予め形成されている絶縁膜などの薄膜を基板に転写して薄膜を形成する薄膜形成装置および薄膜形成方法に関するものである。
【０００２】
【従来の技術】
近年、ＬＳＩの製造に用いるウエハの大口径化や液晶パネルなどの大面積化に伴い、大面積に適合した薄膜形成方法が必要となってきた。また、ＬＳＩ製造技術における多層配線技術の分野においては、多層配線を実現するために絶縁膜の表面を高い精度で平坦化する必要があり、大面積化に加えて、薄膜形成における表面の平坦化技術への要求も高まってきている。そこで、これらの要求を満足すべく、加圧転写方法によって基板に薄膜を形成する薄膜形成技術が提案されている。
【０００３】
この薄膜形成装置としては、例えば特開平１０−１８９５６６号公報に記載された装置がある。この装置では、処理容器の内部に形成される薄膜形成室内において、加熱ヒータを内蔵する試料台が設けられており、薄膜形成対象となる半導体ウエハや液晶パネル用ガラス基板など（以下、「基板」という）を保持可能となっている。また、薄膜形成室内には、試料台の下方に転写板が試料台と対向しながら配置されており、シートフィルムに形成される薄膜を試料台上の基板に対向させながら、該シートフィルムを保持している。なお、この転写板にも、試料台と同様に、加熱ヒータが設けられており、転写板に保持されたシートフィルムを加熱可能となっている。
【０００４】
また、この薄膜形成室には真空ポンプが連通されており、基板を試料台によって保持するとともに、シートフィルムを転写板に保持し、さらに薄膜形成室を密閉した後、真空ポンプによって薄膜形成室内を排気する。また、真空ポンプで薄膜形成室内を排気減圧しながら、基板を保持する試料台と、シートフィルムを保持する転写板とを相互に近接移動させることによって、基板とシートフィルムとを相互に押し付けてシートフィルム上の薄膜を基板に転写する。こうして、基板上に薄膜を形成すると、基板とシートフィルムとを元の位置に移動させた後、薄膜形成室内を大気圧に戻し、薄膜が形成された基板と、薄膜転写後のシートフィルムとを処理容器から搬出している。
【０００５】
【発明が解決しようとする課題】
ところで、従来の加圧転写方式の薄膜形成装置では、基板およびシートフィルムをそれぞれ試料台および転写板にセットした後、真空ポンプによる薄膜形成室の排気減圧を行いながら、基板への薄膜の転写を実行している。しかしながら、従来装置では、真空ポンプにより単に薄膜形成室を排気減圧しているのみで、転写開始前および転写中における薄膜形成室内の圧力（真空度）に関して、特段の配慮がなされておらず、薄膜形成を良好に行う上で改良の余地が残されている。例えば、薄膜を基板に良好に転写するためには薄膜がある程度の流動性を有している必要があるが、転写開始前に薄膜形成室内の圧力が大幅に減圧されてしまうと、その圧力低下によって薄膜材料の溶媒成分が大量に揮発し、その結果、転写開始時点ですでに薄膜の流動性が損なわれてしまい、基板への薄膜の転写を良好に行うことができない場合がある。逆に、転写中に薄膜形成室の減圧が十分に行われていないと、薄膜を基板に転写した際に基板に形成されているパターン、例えばコンタクトホール等と薄膜との間に空隙（ボイド）が残ってしまい、良好な転写が行われない場合があった。このように、薄膜形成室内の圧力に関しては、転写開始前と転写中とで相互に最適値が異なっており、良好な転写処理を実行するためには、薄膜形成室内の圧力を柔軟に、しかも精度良く制御することが重要となってくるが、従来装置ではかかる圧力制御が困難であった。
【０００６】
この発明は上記課題に鑑みなされたものであり、基板への薄膜の転写を良好に行うことができる薄膜形成装置および薄膜形成方法を提供することを目的とする。
【０００７】
【課題を解決するための手段】
すでに「発明が解決しようとする課題」の項で説明したように、基板への薄膜の転写開始前と転写中においては、良好な転写処理を実行するために要望される圧力値（真空度）が相違しているが、この発明では、それぞれにおいて薄膜形成室内の圧力を各々に適した値に制御している。
【０００８】
この発明にかかる薄膜形成装置は、上記目的を達成するため、その内部が薄膜形成室となっている処理容器と、薄膜形成室内で基板を保持する基板保持手段と、薄膜形成室内で基板保持手段に対向配置され、シートフィルムに形成される薄膜を基板に向けた状態で該シートフィルムを保持するフィルム保持手段と、基板保持手段およびフィルム保持手段のうち少なくとも一方を移動させることで、基板とシートフィルムとを相互に押し付けて薄膜を基板に転写する加重手段と、薄膜形成室に連通されて該薄膜形成室を排気する排気部と、排気部と薄膜形成室との間に介挿されて薄膜形成室から排気部への単位時間当たりの排気量を調整可能な排気調整部と、基板とシートフィルムとを相互に押し付けることにより実行される基板への薄膜の転写前における単位時間当たりの排気量を基板への薄膜の転写中における単位時間当たりの排気量よりも少なくなるように排気調整部を制御して薄膜形成室内の圧力を調整する圧力調整部とを備える圧力制御手段とを備えている。
【０００９】
このように構成された装置では、加重手段により基板とシートフィルムとを相互に押し付けることで基板への薄膜の転写を実行するとともに、薄膜形成室内を排気する排気部および該排気部による単位時間当たりの排気量を調整する排気調整部により薄膜形成室内の圧力を制御する。また、排気量調整部は、加重手段により基板とシートフィルムとが相互に押し付けられて基板への薄膜の転写が開始される前における排気量を、基板への薄膜の転写が開始された後における排気量よりも少なく調整する。これにより、転写が開始される前は、シートフィルムに形成された薄膜の流動性が損なわれることを防止するとともに、転写が開始された後は、薄膜形成室内が十分に減圧されるため空隙（ボイド）の発生を防止することができる。したがって良好な転写が可能となる。
【００１０】
また、この発明にかかる薄膜形成装置および方法は、基板とシートフィルムとを相互に押し付けて基板への薄膜の転写が開始される前における排気量を、基板への薄膜の転写が開始された後における排気量よりも少なく調整する。
【００１１】
このように構成された発明では、転写が開始される前は、シートフィルムに形成された薄膜の流動性が損なわれることを防止するとともに、転写が開始された後は、薄膜形成室内が十分に減圧されるため空隙（ボイド）の発生を防止することができる。したがって良好な転写が可能となる。
【００１２】
なお、この明細書において、「転写処理」とは薄膜形成室に搬送されてきた基板およびシートフィルムを相互に近接移動させることで両者を相互に当接させ、さらに両者を相互に押し付けてシートフィルムに形成された薄膜を基板に転写するまでの一連の処理を意味している。
【００１３】
【発明の実施の形態】
図１は、この発明にかかる薄膜形成装置の一実施形態を示す図である。また、図２は図１の薄膜形成装置の部分拡大断面図である。この薄膜形成装置は、その内部が後述するようにして転写処理を行う薄膜形成室１１となっている処理容器１を有している。また、この処理容器１の側面底部には、排気口１２が設けられており、この排気口１２に薄膜形成室１１の圧力を調整する圧力制御ユニット２が接続されている。
【００１４】
この圧力制御ユニット２では、バタフライバルブ２１を介して真空ポンプ２２が薄膜形成室１１と連通されており、バタフライバルブ２１を開いた状態で、装置全体を制御する制御部３からの動作信号に応じて真空ポンプ２２が作動すると、薄膜形成室１１内が排気減圧される。また、圧力制御ユニット２には、バタフライバルブ２１の開度をコントロールするバルブコントローラ２３が設けられており、制御部３からの開度信号に応じてバルブコントローラ２３がバタフライバルブ２１の開閉、さらには開度を調整することで薄膜形成室１１からの単位時間当たりの排気量を調整し、薄膜形成室１１内の圧力（真空度）を制御可能となっている。このように、この実施形態では、バタフライバルブ２１、真空ポンプ２２およびバルブコントローラ２３がそれぞれ本発明の「排気調整部」、「排気部」および「圧力調整部」として機能し、薄膜形成室１１内の圧力を調整可能となっている。なお、この実施形態では、薄膜形成室１１内の圧力を精度良く制御するために、薄膜形成室１１内の圧力を測定する圧力計３１を設け、この圧力計３１の測定結果を制御部３に出力し、この測定結果に基づくフィードバック制御を実行している。
【００１５】
また、この処理容器１の上面周縁部には、導入口１３が設けられており、この導入口１３を介して一定流量の窒素ガスが薄膜形成室１１内に供給されている。すなわち、この導入口１３はマスフローコントローラ１４を介して窒素ガス供給源（図示省略）と接続されており、制御部３から与えられるガス供給信号に基づきマスフローコントローラ１４が導入口１３を介して薄膜形成室１１に供給される窒素ガスの流入量をコントロールしている。なお、この実施形態では、後で説明する転写処理を良好に行うために窒素ガスを供給しているが、薄膜形成室１１に供給するガス種はこれに限定されるものではなく、転写処理に適したガスを供給すればよい。
【００１６】
こうして圧力調整の対象となっている薄膜形成室１１には、第１、第２のプレート４，５が上下に対向して収容されている。これらのプレートのうち、第１のプレート４は、第２のプレート５と対向する下面に薄膜形成対象である基板Ｗを保持可能となっており、本発明の「基板保持手段」として機能している。ここで、薄膜形成対象となる基板Ｗとしては、例えば円板状に形成された半導体ウエハと、この半導体ウエハ上に電極配線としてＡｌ配線をパターニング形成した構造を有するものがあり、以下においては、この基板Ｗのパターニング形成面側に後述する絶縁膜（薄膜）を転写する場合について説明する。
【００１７】
この第１のプレート４の下面には、平坦性を確保するために研磨された石英板４１が設けられており、この石英板４１に基板Ｗが装着される。このように基板Ｗと直接接触する板材４１として石英を用いた理由は、石英が基板Ｗを汚染する物質を含まないこと、および加工性がよく、必要とする平坦性が容易に得られることなどからである。
【００１８】
また、第１のプレート４には、加熱手段として加熱ヒータ６が内蔵されている。この加熱ヒータ６は制御部３から与えられる基板温度信号に基づきヒータコントローラ６１によって制御され、２５°Ｃ〜３００°Ｃの間で加熱制御される。そして、第１のプレート４は処理容器１内に吊設され、加重モータ７１によって昇降されるように構成されている。
【００１９】
また、もう一方のプレート、つまり第２のプレート５は、第１のプレート４の下方に軸線を一致させて配設され、その上面でシートフィルム８を保持可能となっており、本発明の「フィルム保持手段」として機能している。すなわち、この第２のプレート５は、プレート本体５１と、そのプレート本体５１の上面側でシートフィルム８を保持可能な石英製のステージ５２と、シートフィルム８を加熱する加熱ランプ５３とで構成されている。このシートフィルム８は基板Ｗより大きい円形に形成され、表面には薄膜となる絶縁膜８１が形成されている。本実施形態においては、シートフィルム８として熱可塑性樹脂フィルム８２を用いている。薄膜としてはＳＯＧ材料の絶縁膜形成用塗布液を用い、これをシートフィルム８上に塗布することにより１μｍ以上の厚さで絶縁膜８１が形成されている。
【００２０】
このプレート本体５１の上面側には、基板Ｗの平面サイズよりも若干大きな平面サイズで、しかも図２に示すように第１のプレート４を望むように凹部５１１が形成されている。この凹部５１１内には４本の加熱ランプ５３が埋設されるとともに、さらに凹部５１１の開口位置に石英製ステージ５２が配置されている。そして、石英製ステージ５２の上面に、シートフィルム８に形成された絶縁膜８１を上記のように第１のプレート４に保持された基板Ｗに向けた状態で、シートフィルム８が載置可能となっている。
【００２１】
また、プレート本体５１の周縁部には、フィルム保持・緊張部９が配置されており、石英製ステージ５２に載置されたシートフィルム８を絶縁膜８１の転写時に保持するとともに、後で詳述するタイミングでシートフィルム８を緊張させる。
【００２２】
また、加熱ランプ５３は、図１に示すように、ランプコントローラ５４と電気的に接続されており、制御部３から与えられるランプ制御信号に基づきランプコントローラ５４が加熱ランプ５３を点灯／消灯制御する。このため、例えば制御部３から加熱ランプ５３を点灯させる旨のランプ制御信号がランプコントローラ５４に与えられると、加熱ランプ５３が点灯し、加熱ランプ５３から放射される熱線が石英製ステージ５２を通過してシートフィルム８に照射される。これによって、シートフィルム８が２５°Ｃ〜３００°Ｃの間で加熱される。
【００２３】
さらに、第２のプレート５は、支え板７２上において複数の圧縮コイルばね７３によって弾性支持されて配設されることにより、基板Ｗとシートフィルム８を押し付けたとき加重圧力が均一になるようにしている。また、支え板７２は、支柱７４によって上下動自在に保持され、加重モータ７５によって昇降されるように構成されている。このように、この実施形態では、加重モータ７１，７５によって２つのプレート４，５を互いに逆方向に昇降移動させることで次に説明する薄膜形成手順（転写処理）を行っており、加重モータ７１，７５が本発明の「加重手段」として機能している。
【００２４】
次に、上記した薄膜形成装置を使用した薄膜形成手順について説明する。本実施形態においては、第１のプレート４の下面に基板Ｗがパターニング形成面（電極配線を形成した面）を下に向けて装着される。また、第２のプレート５のステージ５２の上方には、図２の１点鎖線で示したシートフィルム８が絶縁膜８１を上に向けて供給され、外周縁部がフィルム保持・緊張部９によって保持される。なお、この段階では、フィルム保持・緊張部９によるシートフィルム８の緊張は行われていない。
【００２５】
こうして、基板Ｗおよびシートフィルム８の搬入および装着が完了する（時刻ｔ1）と、制御部３が予めメモリ（図示省略）に記憶されている転写プログラムにしたがって装置各部を制御し、次に説明する転写処理を実行して絶縁膜８１を基板Ｗに転写する。以下、図３を参照しつつ転写処理について詳述する。なお、同図中のグラフは薄膜形成室１１内の圧力を示すグラフであり、同図中の太実線が本実施形態におけるバタフライバルブ２１の開度状態を示しており、開度が大きくなるにしたがって単位時間当たりの排気量が多くなる。
【００２６】
（１）まず、時刻ｔ1で制御部３からバルブコントローラ２３に、バタフライバルブ２１を１０％開く旨の開度信号が出力される。この信号を受けてバルブコントローラ２３は完全に閉じられたバタフライバルブ２１を一部開いて作動させて真空ポンプ２２による最大排気量の約１０％で薄膜形成室１１の排気減圧を開始する。すると、図３の上段グラフ中の実線（ＡＰＣ有り）に示すように、薄膜形成室１１の圧力は徐々に低下していく。また、時刻ｔ1において、制御部３はマスフローコントローラ１４にガス供給信号を発する。これにより、マスフローコントローラ１４は薄膜形成室１１内の圧力にかかわらず、導入口１３から供給される窒素ガスの流量を一定量に維持する。
【００２７】
（２）そして、所望の圧力まで減圧されると、ヒータコントローラ６１からの制御信号によって加熱ヒータ６に通電して第１のプレート４を約２００°Ｃ程度に加熱し、基板Ｗを所望の温度に加熱する。また、シートフィルム８側についても、加熱ランプ５３を点灯させることで第２のプレート５を約１００°Ｃ程度に加熱するとともに、制御部３より加重モータ７５に信号が送られ、プレート５の昇降移動を開始する。これによって第２のプレート５がシートフィルム８の位置まで上昇してステージ５２をシートフィルム８に接触させる。これによって、シートフィルム８は加熱されて伸張し波状の弛みが発生する。そこで、この実施形態では、フィルム保持・緊張部９によってシートフィルム８を緊張させて熱膨張による波状の弛みを取り除いている。
【００２８】
（３）また、シートフィルム８の緊張とともに、加重モータ７１の駆動によって第１のプレート４を下降させて基板Ｗをシートフィルム８に押し付けて基板Ｗへの絶縁膜８１の転写を開始するとともに、バタフライバルブ２１を１００％開く旨の開度信号を受けてバルブコントローラ２３がバタフライバルブ２１を完全に開いて真空ポンプ２２による最大排気量で薄膜形成室１１を排気減圧する（時刻ｔ2）。こうすることで、図３の上段グラフ中の実線（ＡＰＣ有り）に示すように、薄膜形成室１１の圧力は急激に低下しながら、同時に基板Ｗへの絶縁膜８１の転写が実行される。この転写中（時刻ｔ2以降）においては、バタフライバルブ２１を全開させた状態のまま、基板Ｗとシートフィルム８とは所定の加重で一定時間加圧される。その間も基板Ｗとシートフィルム８は所定の温度となるように加熱されている。
【００２９】
（４）そして、一連の加重操作が終了して転写処理が完了すると、加重の状態が零となるように制御部３から加重モータ７１，７５に信号を送り、第１、第２のプレート４，５を元の初期位置に復帰させる。また、両プレート４，５が初期位置に戻った後、バタフライバルブ２１を閉じるとともに、真空ポンプ２２を停止させる。
【００３０】
（５）次に、薄膜形成室１１の圧力が大気圧に戻るのを待って、制御部からマスフローコントローラ１４にガス供給の停止信号を発する。これにより、薄膜形成室１１への窒素ガスの供給は停止する。また、絶縁膜８１を挟んでシートフィルム８と一体となった状態の基板Ｗを薄膜形成室１１から取り出し、シートフィルム８を剥離することによって絶縁膜８１が形成された基板Ｗを得る。
【００３１】
以上のように、この実施形態によれば、圧力制御ユニット２を設け、上記した動作（１）から（３）からなる転写処理を行っている間、単位時間当たりの排気量を制御して薄膜形成室１１内の圧力を調整しているため、絶縁膜８１を基板Ｗのパターニング形成面に良好に転写することができる。その理由を従来装置と対比して説明する。
【００３２】
従来装置では、転写処理を実行している間、薄膜形成室１１内の圧力を図３の２点鎖線で示すように制御している。すなわち、時刻ｔ1で直ちに真空ポンプ２２の最大排気量で薄膜形成室１１を排気減圧しているため、時刻ｔ1から薄膜形成室１１内の圧力が急速に低下し、その減圧状態（高真空度状態）のまま基板Ｗおよびシートフィルム８の加熱、ならびにシートフィルム８の緊張を行っているため、絶縁膜８１の乾燥が進行して絶縁膜８１の流動性が大きく損なわれてしまい、その後、時刻ｔ2で基板Ｗをシートフィルム８に押し付けて基板Ｗへの絶縁膜８１の転写を開始した際に絶縁膜８１が基板Ｗのパターニング形成面に沿って密着されないことがある。
【００３３】
これに対し、本実施形態によれば、基板Ｗへの絶縁膜８１の転写を開始する前（時刻ｔ1〜ｔ2）においては、バタフライバルブ２１の開度を小さくすることで真空度の上昇を抑えて絶縁膜８１の溶媒成分の揮発を抑制し、転写開始時点（時刻ｔ2）での絶縁膜８１の流動性を確保しているので、上記問題を解消することができる。しかも、転写開始時点からバタフライバルブ２１を全開して薄膜形成室１１の圧力を急激に低下させているので、基板Ｗへの絶縁膜８１の転写は常に低圧状態（高真空度）で実行することができ、良好な転写を行うことができる。また、本実施形態によれば、マスフローコントローラ１４を介して薄膜形成室１１内に窒素ガスを供給しつつ排気口１２から薄膜形成室１１内の雰囲気を排出している。このため,薄膜形成室１１内に浮遊している汚染物質や、不要な溶媒の蒸気を該薄膜形成室１１から排出することができ、良好な転写を行うことができる。
【００３４】
なお、本発明は上記した実施形態に限定されるものではなく、その趣旨を逸脱しない限りにおいて上述したもの以外に種々の変更を行うことが可能である。例えば、上記実施形態では、時刻ｔ1から時刻ｔ2までの間、バタフライバルブ２１の開度を１０％に設定し、時刻ｔ2以降において１００％に設定しているが、各開度値はこれに限定されるものではなく、少なくとも基板Ｗへの絶縁膜８１の転写前における単位時間当たりの排気量が基板Ｗへの絶縁膜８１の転写中における単位時間当たりの排気量よりも少なくなるように設定することで同様の作用効果が得られる。ただし、同一圧力下において絶縁膜８１の材料によって溶媒の揮発度合いが相違することがあるため、絶縁膜８１の材料に応じてバタフライバルブ２１の開度値を設定するのが望ましい。
【００３５】
また、上記実施形態では、転写開始前（時刻ｔ1から時刻ｔ2までの間）においてバタフライバルブ２１の開度を１０％に固定しているが、バタフライバルブ２１の開度を連続的に、あるいはステップ的に変化させるようにしてもよい。
【００３６】
また、上記実施形態では、排気調整部としてバタフライバルブ２１を用いて薄膜形成室１１内の圧力を調整制御しているが、薄膜形成室１１から真空ポンプ２２への排気量を調整可能な調圧機構であれば、この調圧機構をバタフライバルブ２１の代わりに排気調整部として用いることができる。
【００３７】
また、上記実施形態では、排気部として真空ポンプ２２を用いているが、薄膜形成室内を排気することができる排気機構であれば、この排気機構を真空ポンプ２２の代わりに排気部として用いることができる。
【００３８】
また、上記実施形態では、バルブコントローラ２３によりバタフライバルブ２１を制御することで単位時間当たりの排気量を制御しているが、図４および図５に示すように真空ポンプ２２に印加する電圧を制御することで単位時間当たりの排気量を制御するようにしてもよい。
【００３９】
図４は、この発明にかかる薄膜形成装置の他の実施形態を示す図である。この実施形態が図１の実施形態と大きく相違する点は、バタフライバルブ２１およびバルブコントローラ２３の代わりに駆動電圧コントローラ２４を設けている点である。なお、その他の構成は同一である。この薄膜形成装置では、図５に示すように、真空ポンプ２２に印加する駆動電圧を制御することで真空ポンプ２２の排気能力を変化させている。すなわち、基板Ｗへの絶縁膜８１の転写を開始する前（時刻ｔ1〜ｔ2）においては、真空ポンプ２２に印加する駆動電圧を低く設定することで単位時間当たりの排気量を抑制し、真空度の上昇を抑えている。これによって絶縁膜８１の溶媒成分の揮発を抑制し、転写開始時点（時刻ｔ2）での絶縁膜８１の流動性を確保している。一方、転写開始時点から真空ポンプ２２に印加する駆動電圧を最大印加電圧Ｖmaxまで増大させて単位時間当たりの排気量を高めている。これによって、薄膜形成室１１の圧力は急激に低下し、基板Ｗへの絶縁膜８１の転写は常に低圧状態（高真空度）で実行することができ、良好な転写を行うことができる。
【００４０】
なお、ここでは、時刻ｔ1から時刻ｔ2までの間、真空ポンプ２２への印加電圧を最大印加電圧Ｖmaxの１０％に設定し、時刻ｔ2以降において最大印加電圧Ｖmaxに設定しているが、各印加電圧はこれに限定されるものではなく、少なくとも基板Ｗへの絶縁膜８１の転写前における単位時間当たりの排気量が基板Ｗへの絶縁膜８１の転写中における単位時間当たりの排気量よりも少なくなるように設定することで同様の作用効果が得られる。ただし、同一圧力下において絶縁膜８１の材料によって溶媒の揮発度合いが相違することがあるため、絶縁膜８１の材料に応じて印加電圧を設定するのが望ましい。また、印加電圧を連続的に、あるいはステップ的に変化させるようにしてもよい。
【００４１】
また、上記実施形態では、第１のプレート４を基板保持手段として機能させるとともに、第２のプレート５をフィルム保持手段として機能させているが、第２のプレート５を基板保持手段として機能させるとともに、第１のプレート４をフィルム保持手段として機能させるように構成してもよい。
【００４２】
また、上記実施形態では、シートフィルム８を円板状に形成し、一枚ずつ第１、第２のプレート４，５間に供給し、シートフィルム８を押圧するようにした薄膜形成装置に適用したが、ロール状のシートフィルムを用いた薄膜形成装置にもそのまま適用することができる。また、上記した実施形態では、第１のプレート４と第２のプレート５を加重モータ７１，７５によって昇降させるようにしたが、いずれか一方のみが昇降する構成とすることも可能である。また、加重機構としてモータ７１，７５を用いて加重するようにしているが、これに限らず、第１、第２のプレート４，５を加圧する機構であれば他の手段であってもよい。
【００４３】
また、上記実施形態では、熱可塑性合成樹脂フィルムによるシートフィルム８を用いたが、これに限らず、金属系フィルムなどでもよいことはいうまでもない。
【００４４】
さらに、上記実施形態では、シートフィルム８に絶縁膜を形成するようにしたが、シートフィルム上に形成可能な薄膜であれば絶縁膜に限るものではなく、他の薄膜、例えば金属系の薄膜を形成してもよい。さらに、上記した実施形態では、半導体基板に薄膜を形成する例を示したが、これに限らず、電子部品材料関係であればマルチチップモジュール等の実装関係の基板や液晶関係の基板にも適用できることはいうまでもない。
【００４５】
【発明の効果】
以上のように、この発明によれば、加重手段により基板とシートフィルムとを相互に押し付けることで基板への薄膜の転写を実行するとともに、薄膜形成室内を排気する排気部および該排気部による単位時間当たりの排気量を調整する排気調整部により薄膜形成室内の圧力を制御する。また、排気量調整部は、加重手段により基板とシートフィルムとが相互に押し付けられて基板への薄膜の転写が開始される前における排気量を、基板への薄膜の転写が開始された後における排気量よりも少なく調整する。これにより、転写が開始される前は、シートフィルムに形成された薄膜の流動性が損なわれることを防止するとともに、転写が開始された後は、薄膜形成室内が十分に減圧されるため空隙（ボイド）の発生を防止することができる。したがって良好な転写が可能となる。
【図面の簡単な説明】
【図１】この発明にかかる薄膜形成装置の一実施形態を示す図である。
【図２】図１の薄膜形成装置の部分拡大断面図である。
【図３】図１の薄膜形成装置の動作を示す図である。
【図４】この発明にかかる薄膜形成装置の他の実施形態を示す図である。
【図５】図４の薄膜形成装置の動作を示す図である。
【符号の説明】
１…処理容器
２…圧力制御ユニット
３…制御部
４…第１のプレート（基板保持手段）
５…第２のプレート（フィルム保持手段）
８…シートフィルム
１１…薄膜形成室
１２…排気口
２１…バタフライバルブ（排気調整部）
２２…真空ポンプ（排気部）
２３…バルブコントローラ（圧力調整部）
７１，７５…加重モータ（加重手段）
８１…絶縁膜（薄膜）
８２…熱可塑性樹脂フィルム
Ｗ…基板[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a thin film forming apparatus and a thin film forming method for forming a thin film by transferring a thin film such as an insulating film previously formed on the sheet film to the substrate by pressing the substrate and the sheet film against each other in the thin film forming chamber. Is.
[0002]
[Prior art]
In recent years, with an increase in the diameter of a wafer used for manufacturing an LSI and an increase in the area of a liquid crystal panel or the like, a thin film forming method suitable for the large area has become necessary. In addition, in the field of multilayer wiring technology in LSI manufacturing technology, it is necessary to planarize the surface of the insulating film with high accuracy in order to realize multilayer wiring. In addition to increasing the area, planarizing the surface in thin film formation The demand for technology is also increasing. Accordingly, in order to satisfy these requirements, a thin film forming technique for forming a thin film on a substrate by a pressure transfer method has been proposed.
[0003]
As this thin film forming apparatus, for example, there is an apparatus described in JP-A-10-189666. In this apparatus, a sample stage with a built-in heater is provided in a thin film forming chamber formed inside a processing container, such as a semiconductor wafer or a glass substrate for a liquid crystal panel (hereinafter referred to as “substrate”). Can be held). In the thin film forming chamber, a transfer plate is arranged below the sample table so as to face the sample table, and the thin film formed on the sheet film is held while facing the substrate on the sample table. is doing. The transfer plate is also provided with a heater similarly to the sample stage, so that the sheet film held on the transfer plate can be heated.
[0004]
In addition, a vacuum pump is connected to the thin film forming chamber. The substrate is held by the sample stage, the sheet film is held on the transfer plate, and the thin film forming chamber is sealed. Exhaust. Also, the substrate and the sheet film are pressed against each other by moving the sample table holding the substrate and the transfer plate holding the sheet film close to each other while the vacuum pump exhausts and decompresses the thin film forming chamber. The thin film on the film is transferred to the substrate. Thus, when a thin film is formed on the substrate, the substrate and the sheet film are moved to their original positions, then the inside of the thin film forming chamber is returned to atmospheric pressure, and the substrate on which the thin film is formed and the sheet film after the thin film transfer are moved. Removed from the processing container.
[0005]
[Problems to be solved by the invention]
By the way, in the conventional pressure transfer type thin film forming apparatus, the substrate and the sheet film are set on the sample stage and the transfer plate, respectively, and then the thin film is transferred to the substrate while the thin film forming chamber is evacuated and reduced by a vacuum pump. Running. However, in the conventional apparatus, the thin film formation chamber is simply evacuated and decompressed by a vacuum pump, and no special consideration is given to the pressure (vacuum degree) in the thin film formation chamber before and during the transfer. There is still room for improvement in terms of good formation. For example, in order to transfer the thin film to the substrate satisfactorily, the thin film needs to have a certain degree of fluidity, but if the pressure in the thin film forming chamber is greatly reduced before the transfer starts, the pressure drops As a result, a large amount of the solvent component of the thin film material is volatilized, and as a result, the fluidity of the thin film is already impaired at the start of transfer, and the thin film cannot be successfully transferred to the substrate. Conversely, if the thin film formation chamber is not sufficiently depressurized during transfer, a void is formed between the pattern formed on the substrate when the thin film is transferred to the substrate, such as a contact hole and the thin film. May remain, and good transfer may not be performed. As described above, the optimum values for the pressure in the thin film forming chamber are different before and during the transfer, and the pressure in the thin film forming chamber is flexible in order to perform a good transfer process. Although it is important to control with high accuracy, it is difficult to control the pressure with the conventional apparatus.
[0006]
This invention is made | formed in view of the said subject, and it aims at providing the thin film formation apparatus and thin film formation method which can perform the transfer of the thin film to a board | substrate favorably.
[0007]
[Means for Solving the Problems]
As already described in the section “Problems to be solved by the invention”, the pressure value (degree of vacuum) required for executing a good transfer process before and during the transfer of the thin film to the substrate. In the present invention, the pressure in the thin film forming chamber is controlled to a value suitable for each.
[0008]
In order to achieve the above object, a thin film forming apparatus according to the present invention includes a processing container having a thin film forming chamber therein, a substrate holding means for holding a substrate in the thin film forming chamber, and a substrate holding means in the thin film forming chamber. A film holding means for holding the sheet film in a state where the thin film formed on the sheet film faces the substrate, and moving the substrate and the sheet by moving at least one of the substrate holding means and the film holding means. Weighting means for pressing the film against each other and transferring the thin film to the substrate, an exhaust part communicating with the thin film forming chamber for exhausting the thin film forming chamber, and a thin film interposed between the exhaust part and the thin film forming chamber The thin film is transferred to the substrate, which is executed by pressing the substrate and the sheet film against each other, and the exhaust adjustment unit capable of adjusting the exhaust amount per unit time from the forming chamber to the exhaust unit. A pressure adjusting unit that controls the exhaust adjusting unit to adjust the pressure in the thin film forming chamber so that the previous exhaust amount per unit time is smaller than the exhaust amount per unit time during transfer of the thin film to the substrate. Pressure control means.
[0009]
In the apparatus configured as described above, the thin film is transferred to the substrate by pressing the substrate and the sheet film against each other by the weighting unit, and the exhaust unit for exhausting the thin film forming chamber and the unit per unit time by the exhaust unit The pressure in the thin film forming chamber is controlled by an exhaust adjustment unit that adjusts the amount of exhaust gas. Further, the exhaust amount adjusting unit determines the exhaust amount before the transfer of the thin film to the substrate is started after the substrate and the sheet film are pressed against each other by the weighting means, and after the transfer of the thin film to the substrate is started. Adjust less than the displacement. Thereby, before the transfer is started, the fluidity of the thin film formed on the sheet film is prevented from being impaired, and after the transfer is started, the inside of the thin film forming chamber is sufficiently decompressed so that the gap ( Generation of voids can be prevented. Therefore, good transfer is possible.
[0010]
Further, the thin film forming apparatus and method according to the present invention are configured such that the amount of exhaust gas before the transfer of the thin film to the substrate is started by pressing the substrate and the sheet film to each other, and the transfer of the thin film to the substrate is started. Adjust less than the amount of exhaust.
[0011]
In the invention configured as described above, before the transfer is started, the fluidity of the thin film formed on the sheet film is prevented from being impaired, and after the transfer is started, the thin film forming chamber is sufficiently provided. Since the pressure is reduced, the generation of voids can be prevented. Therefore, good transfer is possible.
[0012]
In this specification, “transfer processing” means that the substrate and sheet film conveyed to the thin film forming chamber are moved close to each other so that they are brought into contact with each other and further pressed against each other. This means a series of processes until the thin film formed on the substrate is transferred to the substrate.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a view showing an embodiment of a thin film forming apparatus according to the present invention. FIG. 2 is a partially enlarged sectional view of the thin film forming apparatus of FIG. This thin film forming apparatus has a processing container 1 whose inside is a thin film forming chamber 11 for performing a transfer process as described later. An exhaust port 12 is provided at the bottom of the side surface of the processing container 1, and a pressure control unit 2 that adjusts the pressure in the thin film forming chamber 11 is connected to the exhaust port 12.
[0014]
In this pressure control unit 2, a vacuum pump 22 is communicated with the thin film forming chamber 11 via a butterfly valve 21, and in response to an operation signal from the control unit 3 that controls the entire apparatus with the butterfly valve 21 opened. When the vacuum pump 22 is activated, the inside of the thin film forming chamber 11 is evacuated and decompressed. Further, the pressure control unit 2 is provided with a valve controller 23 for controlling the opening degree of the butterfly valve 21, and the valve controller 23 opens and closes the butterfly valve 21 according to the opening degree signal from the control unit 3. By adjusting the opening degree, the exhaust amount per unit time from the thin film forming chamber 11 can be adjusted, and the pressure (degree of vacuum) in the thin film forming chamber 11 can be controlled. As described above, in this embodiment, the butterfly valve 21, the vacuum pump 22, and the valve controller 23 function as the “exhaust adjusting unit”, “exhaust unit”, and “pressure adjusting unit” of the present invention, respectively. The pressure can be adjusted. In this embodiment, in order to accurately control the pressure in the thin film forming chamber 11, a pressure gauge 31 for measuring the pressure in the thin film forming chamber 11 is provided, and the measurement result of the pressure gauge 31 is sent to the control unit 3. Output and feedback control based on the measurement result is executed.
[0015]
In addition, an inlet 13 is provided on the peripheral edge of the upper surface of the processing container 1, and nitrogen gas at a constant flow rate is supplied into the thin film forming chamber 11 through the inlet 13. That is, the introduction port 13 is connected to a nitrogen gas supply source (not shown) via a mass flow controller 14, and the mass flow controller 14 forms a thin film via the introduction port 13 based on a gas supply signal given from the control unit 3. The inflow amount of nitrogen gas supplied to the chamber 11 is controlled. In this embodiment, nitrogen gas is supplied in order to satisfactorily perform the transfer process described later. However, the gas type supplied to the thin film forming chamber 11 is not limited to this, and the transfer process is not limited thereto. A suitable gas may be supplied.
[0016]
Thus, the first and second plates 4 and 5 are accommodated in the thin film forming chamber 11 which is the object of pressure adjustment, facing each other vertically. Among these plates, the first plate 4 can hold the substrate W as a thin film formation target on the lower surface facing the second plate 5 and functions as the “substrate holding means” of the present invention. Yes. Here, as the substrate W to be a thin film formation target, there is, for example, a semiconductor wafer formed in a disk shape, and a substrate having a structure in which an Al wiring is patterned as an electrode wiring on the semiconductor wafer. A case where an insulating film (thin film) to be described later is transferred to the patterning surface side of the substrate W will be described.
[0017]
A quartz plate 41 polished to ensure flatness is provided on the lower surface of the first plate 4, and a substrate W is mounted on the quartz plate 41. The reason why quartz is used as the plate material 41 in direct contact with the substrate W in this way is that the quartz does not contain a substance that contaminates the substrate W, that workability is good, and necessary flatness can be easily obtained. Because.
[0018]
The first plate 4 includes a heater 6 as a heating means. The heater 6 is controlled by a heater controller 61 based on a substrate temperature signal given from the control unit 3, and is controlled to be heated between 25 ° C. and 300 ° C. The first plate 4 is suspended in the processing container 1 and is lifted and lowered by a weighted motor 71.
[0019]
The other plate, that is, the second plate 5 is disposed below the first plate 4 with the axis line aligned, and can hold the sheet film 8 on the upper surface thereof. It functions as “film holding means”. That is, the second plate 5 includes a plate body 51, a quartz stage 52 that can hold the sheet film 8 on the upper surface side of the plate body 51, and a heating lamp 53 that heats the sheet film 8. ing. The sheet film 8 is formed in a circular shape larger than the substrate W, and an insulating film 81 that is a thin film is formed on the surface. In the present embodiment, a thermoplastic resin film 82 is used as the sheet film 8. As the thin film, an insulating film forming coating solution of SOG material is used, and this is applied onto the sheet film 8 to form the insulating film 81 with a thickness of 1 μm or more.
[0020]
A concave portion 511 is formed on the upper surface side of the plate main body 51 so as to have a slightly larger planar size than the planar size of the substrate W, and the first plate 4 is desired as shown in FIG. Four heating lamps 53 are embedded in the recess 511, and a quartz stage 52 is disposed at the opening position of the recess 511. The sheet film 8 can be placed on the upper surface of the quartz stage 52 with the insulating film 81 formed on the sheet film 8 facing the substrate W held on the first plate 4 as described above. It has become.
[0021]
Further, a film holding / tensioning portion 9 is disposed at the peripheral edge of the plate body 51, and holds the sheet film 8 placed on the quartz stage 52 during the transfer of the insulating film 81 and will be described in detail later. The sheet film 8 is tensioned at the timing to perform.
[0022]
Further, as shown in FIG. 1, the heating lamp 53 is electrically connected to the lamp controller 54, and the lamp controller 54 controls the heating lamp 53 to be turned on / off based on a lamp control signal given from the control unit 3. . Therefore, for example, when a lamp control signal for turning on the heating lamp 53 is given from the control unit 3 to the lamp controller 54, the heating lamp 53 is turned on, and the heat rays emitted from the heating lamp 53 pass through the quartz stage 52. Then, the sheet film 8 is irradiated. Thereby, the sheet film 8 is heated between 25 ° C. and 300 ° C.
[0023]
Further, the second plate 5 is elastically supported on the support plate 72 by a plurality of compression coil springs 73 so that the load pressure becomes uniform when the substrate W and the sheet film 8 are pressed. ing. The support plate 72 is configured to be vertically movable by a support column 74 and to be lifted and lowered by a load motor 75. Thus, in this embodiment, the thin film formation procedure (transfer process) described below is performed by moving the two plates 4 and 5 up and down in opposite directions by the weight motors 71 and 75. , 75 function as the “weighting means” of the present invention.
[0024]
Next, a procedure for forming a thin film using the above-described thin film forming apparatus will be described. In the present embodiment, the substrate W is mounted on the lower surface of the first plate 4 with the patterning formation surface (surface on which the electrode wiring is formed) facing down. Also, above the stage 52 of the second plate 5, the sheet film 8 indicated by the one-dot chain line in FIG. 2 is supplied with the insulating film 81 facing upward, and the outer peripheral edge portion is provided by the film holding / tensioning portion 9. Retained. At this stage, the tension of the sheet film 8 by the film holding / tensioning portion 9 is not performed.
[0025]
Thus, when the loading and mounting of the substrate W and the sheet film 8 are completed (time t1), the control unit 3 controls each part of the apparatus in accordance with a transfer program stored in advance in a memory (not shown). A transfer process is performed to transfer the insulating film 81 to the substrate W. Hereinafter, the transfer process will be described in detail with reference to FIG. In addition, the graph in the figure is a graph which shows the pressure in the thin film formation chamber 11, and the thick solid line in the figure has shown the opening degree state of the butterfly valve 21 in this embodiment, and an opening degree becomes large. Therefore, the amount of exhaust per unit time increases.
[0026]
(1) First, at time t1, an opening degree signal indicating that the butterfly valve 21 is opened by 10% is output from the control unit 3 to the valve controller 23. In response to this signal, the valve controller 23 opens and operates a partly closed butterfly valve 21 to start exhaust pressure reduction of the thin film forming chamber 11 at about 10% of the maximum exhaust amount by the vacuum pump 22. Then, as shown by the solid line (with APC) in the upper graph of FIG. 3, the pressure in the thin film forming chamber 11 gradually decreases. At time t1, the control unit 3 issues a gas supply signal to the mass flow controller 14. Thereby, the mass flow controller 14 maintains the flow rate of the nitrogen gas supplied from the inlet 13 at a constant amount regardless of the pressure in the thin film forming chamber 11.
[0027]
(2) When the pressure is reduced to a desired pressure, the heater 6 is energized by a control signal from the heater controller 61 to heat the first plate 4 to about 200 ° C., and the substrate W is heated to a desired temperature. Heat to. On the sheet film 8 side as well, the second lamp 5 is heated to about 100 ° C. by turning on the heating lamp 53, and a signal is sent from the controller 3 to the weighting motor 75 to raise and lower the plate 5. Start moving. As a result, the second plate 5 rises to the position of the sheet film 8 to bring the stage 52 into contact with the sheet film 8. As a result, the sheet film 8 is heated and stretched to generate wavy slack. Therefore, in this embodiment, the sheet film 8 is tensioned by the film holding / tensioning portion 9 to remove wavy slack due to thermal expansion.
[0028]
(3) Also, along with the tension of the sheet film 8, the first plate 4 is lowered by driving the weighting motor 71 to press the substrate W against the sheet film 8 to start the transfer of the insulating film 81 to the substrate W. In response to the opening signal indicating that the butterfly valve 21 is opened 100%, the valve controller 23 completely opens the butterfly valve 21 and exhausts and depressurizes the thin film forming chamber 11 with the maximum displacement by the vacuum pump 22 (time t2). As a result, as shown by the solid line (with APC) in the upper graph of FIG. 3, the pressure of the thin film forming chamber 11 is rapidly reduced, and at the same time, the transfer of the insulating film 81 to the substrate W is executed. During this transfer (after time t2), the substrate W and the sheet film 8 are pressurized with a predetermined load for a predetermined time while the butterfly valve 21 is fully opened. In the meantime, the substrate W and the sheet film 8 are heated to a predetermined temperature.
[0029]
(4) When a series of weighting operations are completed and the transfer process is completed, a signal is sent from the control unit 3 to the weighting motors 71 and 75 so that the weighting state becomes zero, and the first and second plates 4 , 5 are returned to their original initial positions. Moreover, after both plates 4 and 5 return to the initial position, the butterfly valve 21 is closed and the vacuum pump 22 is stopped.
[0030]
(5) Next, after the pressure in the thin film forming chamber 11 returns to atmospheric pressure, a gas supply stop signal is issued from the control unit to the mass flow controller 14. Thereby, the supply of nitrogen gas to the thin film forming chamber 11 is stopped. Further, the substrate W integrated with the sheet film 8 with the insulating film 81 interposed therebetween is taken out from the thin film forming chamber 11 and the sheet film 8 is peeled off to obtain the substrate W on which the insulating film 81 is formed.
[0031]
As described above, according to this embodiment, the pressure control unit 2 is provided, and the amount of exhaust per unit time is controlled while the transfer process including the operations (1) to (3) is performed. Since the pressure in the formation chamber 11 is adjusted, the insulating film 81 can be satisfactorily transferred to the patterning surface of the substrate W. The reason will be described in comparison with a conventional apparatus.
[0032]
In the conventional apparatus, the pressure in the thin film forming chamber 11 is controlled as indicated by a two-dot chain line in FIG. 3 while performing the transfer process. That is, since the thin film forming chamber 11 is immediately evacuated and depressurized with the maximum displacement of the vacuum pump 22 at time t1, the pressure in the thin film forming chamber 11 rapidly decreases from time t1, and the reduced pressure state (high vacuum state) ), The substrate W and the sheet film 8 are heated and the sheet film 8 is tensioned, so that the drying of the insulating film 81 proceeds and the fluidity of the insulating film 81 is greatly impaired. When the substrate W is pressed against the sheet film 8 and the transfer of the insulating film 81 to the substrate W is started, the insulating film 81 may not adhere to the patterning surface of the substrate W.
[0033]
On the other hand, according to the present embodiment, before the transfer of the insulating film 81 to the substrate W is started (time t1 to t2), the increase in the degree of vacuum is suppressed by reducing the opening degree of the butterfly valve 21. Thus, the volatilization of the solvent component of the insulating film 81 is suppressed, and the fluidity of the insulating film 81 at the transfer start time (time t2) is secured, so that the above problem can be solved. In addition, since the butterfly valve 21 is fully opened from the start of transfer and the pressure in the thin film forming chamber 11 is drastically reduced, the transfer of the insulating film 81 to the substrate W is always performed in a low pressure state (high vacuum). And good transfer can be performed. Further, according to the present embodiment, the atmosphere in the thin film forming chamber 11 is discharged from the exhaust port 12 while supplying nitrogen gas into the thin film forming chamber 11 via the mass flow controller 14. For this reason, contaminants floating in the thin film forming chamber 11 and unnecessary solvent vapor can be discharged from the thin film forming chamber 11, and good transfer can be performed.
[0034]
The present invention is not limited to the above-described embodiment, and various modifications other than those described above can be made without departing from the spirit of the present invention. For example, in the above embodiment, the opening degree of the butterfly valve 21 is set to 10% from time t1 to time t2, and is set to 100% after time t2, but each opening value is limited to this. However, at least the amount of exhaust per unit time before the transfer of the insulating film 81 to the substrate W is set to be smaller than the amount of exhaust per unit time during the transfer of the insulating film 81 to the substrate W. The same effect can be obtained. However, since the degree of volatilization of the solvent may differ depending on the material of the insulating film 81 under the same pressure, it is desirable to set the opening value of the butterfly valve 21 according to the material of the insulating film 81.
[0035]
In the above embodiment, the opening degree of the butterfly valve 21 is fixed at 10% before the start of transfer (between time t1 and time t2), but the opening degree of the butterfly valve 21 is continuously or stepwise. It may be changed as desired.
[0036]
Moreover, in the said embodiment, although the pressure in the thin film formation chamber 11 is adjusted and controlled using the butterfly valve 21 as an exhaust_gas | exhaustion adjustment part, the pressure regulation which can adjust the exhaust_gas | exhaustion amount from the thin film formation chamber 11 to the vacuum pump 22 is possible. If it is a mechanism, this pressure regulation mechanism can be used as an exhaust adjustment part instead of the butterfly valve 21.
[0037]
In the above embodiment, the vacuum pump 22 is used as the exhaust unit. However, if the exhaust mechanism can exhaust the thin film forming chamber, the exhaust mechanism can be used as the exhaust unit instead of the vacuum pump 22. it can.
[0038]
Further, in the above embodiment, the exhaust amount per unit time is controlled by controlling the butterfly valve 21 by the valve controller 23. However, as shown in FIGS. 4 and 5, the voltage applied to the vacuum pump 22 is controlled. By doing so, the exhaust amount per unit time may be controlled.
[0039]
FIG. 4 is a view showing another embodiment of the thin film forming apparatus according to the present invention. This embodiment is greatly different from the embodiment of FIG. 1 in that a drive voltage controller 24 is provided instead of the butterfly valve 21 and the valve controller 23. Other configurations are the same. In this thin film forming apparatus, as shown in FIG. 5, the exhaust voltage of the vacuum pump 22 is changed by controlling the drive voltage applied to the vacuum pump 22. That is, before the transfer of the insulating film 81 to the substrate W is started (time t1 to t2), the exhaust voltage per unit time is suppressed by setting the drive voltage applied to the vacuum pump 22 low, and the degree of vacuum The rise of the is suppressed. This suppresses the volatilization of the solvent component of the insulating film 81, and ensures the fluidity of the insulating film 81 at the transfer start time (time t2). On the other hand, the drive voltage applied to the vacuum pump 22 from the transfer start time is increased to the maximum applied voltage Vmax to increase the exhaust amount per unit time. As a result, the pressure in the thin film forming chamber 11 rapidly decreases, and the transfer of the insulating film 81 to the substrate W can always be performed in a low pressure state (high vacuum degree), and good transfer can be performed.
[0040]
In this case, the voltage applied to the vacuum pump 22 is set to 10% of the maximum applied voltage Vmax from time t1 to time t2, and is set to the maximum applied voltage Vmax after time t2. The voltage is not limited to this, and at least the exhaust amount per unit time before the transfer of the insulating film 81 to the substrate W is smaller than the exhaust amount per unit time during the transfer of the insulating film 81 to the substrate W. Similar effects can be obtained by setting so as to be. However, since the degree of volatilization of the solvent may differ depending on the material of the insulating film 81 under the same pressure, it is desirable to set the applied voltage according to the material of the insulating film 81. Further, the applied voltage may be changed continuously or stepwise.
[0041]
In the above embodiment, the first plate 4 functions as the substrate holding means and the second plate 5 functions as the film holding means. However, the second plate 5 functions as the substrate holding means. The first plate 4 may be configured to function as a film holding unit.
[0042]
Moreover, in the said embodiment, it applies to the thin film formation apparatus which formed the sheet | seat film 8 in the disk shape, supplied between the 1st, 2nd plates 4 and 5 one by one, and pressed the sheet | seat film 8. However, the present invention can also be applied to a thin film forming apparatus using a roll-shaped sheet film. In the above-described embodiment, the first plate 4 and the second plate 5 are moved up and down by the weighting motors 71 and 75. However, only one of them can be moved up and down. Further, although the motors 71 and 75 are used as the weighting mechanism, the weight is applied. However, the present invention is not limited to this, and any other means may be used as long as the mechanism pressurizes the first and second plates 4 and 5. .
[0043]
Moreover, in the said embodiment, although the sheet film 8 by a thermoplastic synthetic resin film was used, it cannot be overemphasized that a metal-type film etc. may be sufficient not only in this.
[0044]
Furthermore, in the said embodiment, although the insulating film was formed in the sheet film 8, if it is a thin film which can be formed on a sheet film, it will not restrict to an insulating film, For example, other thin films, for example, a metallic thin film, are used. It may be formed. Furthermore, in the above-described embodiments, an example in which a thin film is formed on a semiconductor substrate has been shown. Needless to say, it can be done.
[0045]
【The invention's effect】
As described above, according to the present invention, the thin film is transferred to the substrate by pressing the substrate and the sheet film against each other by the weighting means, and the exhaust unit for exhausting the thin film forming chamber and the unit by the exhaust unit The pressure in the thin film forming chamber is controlled by an exhaust adjustment unit that adjusts the exhaust amount per hour. Further, the exhaust amount adjusting unit determines the exhaust amount before the transfer of the thin film to the substrate after the substrate and the sheet film are pressed against each other by the weighting means, and after the transfer of the thin film to the substrate is started. Adjust less than the displacement. Thereby, before the transfer is started, the fluidity of the thin film formed on the sheet film is prevented from being impaired, and after the transfer is started, the inside of the thin film forming chamber is sufficiently depressurized so that the gap ( Generation of voids can be prevented. Therefore, good transfer is possible.
[Brief description of the drawings]
FIG. 1 is a view showing an embodiment of a thin film forming apparatus according to the present invention.
FIG. 2 is a partially enlarged cross-sectional view of the thin film forming apparatus of FIG.
3 is a diagram showing an operation of the thin film forming apparatus of FIG. 1. FIG.
FIG. 4 is a view showing another embodiment of a thin film forming apparatus according to the present invention.
5 is a diagram showing an operation of the thin film forming apparatus of FIG. 4. FIG.
[Explanation of symbols]
1 ... Processing container
2 ... Pressure control unit
3. Control unit
4. First plate (substrate holding means)
5 ... Second plate (film holding means)
8 ... Sheet film
11 ... Thin film formation chamber
12 ... Exhaust port
21 ... Butterfly valve (exhaust adjustment part)
22 ... Vacuum pump (exhaust part)
23. Valve controller (pressure adjustment part)
71, 75 ... Weighted motor (weighting means)
81. Insulating film (thin film)
82 ... thermoplastic resin film
W ... Board

Claims (6)

その内部が薄膜形成室となっている処理容器と、
前記薄膜形成室内で基板を保持する基板保持手段と、
前記薄膜形成室内で前記基板保持手段に対向配置され、シートフィルムに形成される薄膜を前記基板に向けた状態で該シートフィルムを保持するフィルム保持手段と、
前記基板保持手段および前記フィルム保持手段のうち少なくとも一方を移動させることで、前記基板と前記シートフィルムとを相互に押し付けて前記薄膜を前記基板に転写する加重手段と、
前記薄膜形成室に連通されて前記薄膜形成室内を排気する排気部と、前記排気部と前記薄膜形成室との間に介挿されて前記薄膜形成室から前記排気部への単位時間当たりの排気量を調整可能な排気調整部と、前記基板と前記シートフィルムとを相互に押し付けることにより実行される前記基板への前記薄膜の転写前における単位時間当たりの排気量を前記基板への前記薄膜の転写中における単位時間当たりの排気量よりも少なくなるように前記排気調整部を制御して前記薄膜形成室内の圧力を調整する圧力調整部とを備える圧力制御手段と
を備えたことを特徴とする薄膜形成装置。A processing container whose inside is a thin film forming chamber;
Substrate holding means for holding the substrate in the thin film forming chamber;
A film holding means which is disposed opposite to the substrate holding means in the thin film forming chamber and holds the sheet film in a state where the thin film formed on the sheet film faces the substrate;
A weighting means for transferring the thin film to the substrate by pressing at least one of the substrate holding means and the film holding means to press the substrate and the sheet film against each other;
An exhaust unit communicating with the thin film forming chamber and exhausting the thin film forming chamber; and an exhaust per unit time from the thin film forming chamber to the exhaust unit interposed between the exhaust unit and the thin film forming chamber The amount of exhaust per unit time before the transfer of the thin film to the substrate, which is executed by pressing the substrate and the sheet film against each other, and the exhaust adjustment unit capable of adjusting the amount of exhaust gas per unit time to the substrate Pressure control means comprising a pressure adjusting unit that controls the exhaust adjusting unit to adjust the pressure in the thin film forming chamber so as to be smaller than the exhaust amount per unit time during the transfer. A thin film forming apparatus. 前記圧力制御手段は、前記薄膜形成室に連通されて前記薄膜形成室を排気する排気部と、前記排気部と前記薄膜形成室との間に介挿されて前記薄膜形成室から前記排気部への単位時間当たりの排気量を調整可能なバルブと、前記基板と前記シートフィルムとを相互に押し付けることにより実行される前記基板への前記薄膜の転写前における前記バルブの開度を前記薄膜形成室から前記排気部への単位時間当たりの排気量が前記排気部の最大排気量の約１０％となるように制御するとともに前記基板への前記薄膜の転写中は前記薄膜形成室から前記排気部への単位時間当たりの排気量が前記排気部の最大排気量の約１００％となるように前記バルブの開度を制御して前記薄膜形成室内の圧力を調整する圧力調整部とを備えている請求項１記載の薄膜形成装置。The pressure control means communicates with the thin film forming chamber and exhausts the thin film forming chamber, and is interposed between the exhaust portion and the thin film forming chamber to pass from the thin film forming chamber to the exhaust portion. A valve capable of adjusting an exhaust amount per unit time, and an opening degree of the valve before the transfer of the thin film to the substrate, which is performed by pressing the substrate and the sheet film against each other. The exhaust amount per unit time from the exhaust portion to the exhaust portion is controlled to be about 10% of the maximum exhaust amount of the exhaust portion, and the thin film is transferred from the thin film forming chamber to the exhaust portion during the transfer of the thin film to the substrate. And a pressure adjusting unit that adjusts the pressure in the thin film forming chamber by controlling the opening degree of the valve so that the exhaust amount per unit time is about 100% of the maximum exhaust amount of the exhaust unit. Item 1 Film forming apparatus. 前記圧力制御手段は、前記薄膜形成室に連通されて前記薄膜形成室内を排気する排気ポンプと、前記排気ポンプに電圧を印加して前記排気ポンプの単位時間当たりの排気量を制御するとともに、前記基板と前記シートフィルムとを相互に押し付けることにより実行される前記基板への前記薄膜の転写前において前記排気ポンプに印加する電圧を、前記基板への前記薄膜の転写中において前記排気ポンプに印加する電圧よりも低く制御して前記薄膜形成室内の圧力を調整する圧力調整部とを備えている請求項１記載の薄膜形成装置。The pressure control means communicates with the thin film forming chamber and exhausts the thin film forming chamber, applies a voltage to the exhaust pump to control the exhaust amount per unit time of the exhaust pump, and A voltage applied to the exhaust pump before the transfer of the thin film to the substrate, which is executed by pressing the substrate and the sheet film against each other, is applied to the exhaust pump during the transfer of the thin film to the substrate. The thin film forming apparatus according to claim 1, further comprising a pressure adjusting unit that controls the pressure in the thin film forming chamber by controlling the voltage lower than the voltage. 薄膜形成室内で基板とシートフィルムとを相互に押し付けることにより前記シートフィルムの基板側主面に形成されている薄膜を前記基板に転写して薄膜を形成する薄膜形成装置において、
前記薄膜形成室を排気する排気手段と、
前記基板と前記シートフィルムとを相互に押し付けることにより実行される前記基板への前記薄膜の転写前における前記排気手段による前記薄膜形成室からの単位時間当たりの排気量を、前記基板への前記薄膜の転写中における前記排気手段による前記薄膜形成室からの単位時間当たりの排気量よりも少なくなるように調整し前記薄膜形成室内の圧力を制御する圧力制御手段と
を備えたことを特徴とする薄膜形成装置。In the thin film forming apparatus for forming a thin film by transferring the thin film formed on the substrate-side main surface of the sheet film to the substrate by pressing the substrate and the sheet film against each other in the thin film forming chamber,
An exhaust means for exhausting the thin film forming chamber;
The amount of exhaust per unit time from the thin film forming chamber by the exhaust means before the transfer of the thin film to the substrate, which is performed by pressing the substrate and the sheet film against each other, is determined as the thin film to the substrate. Pressure control means for controlling the pressure in the thin film formation chamber by adjusting so that the exhaust amount from the thin film formation chamber by the exhaust means during the transfer is less than the exhaust amount per unit time. A thin film forming apparatus. 薄膜形成室内で基板とシートフィルムとを相互に押し付けることにより前記シートフィルムの基板側主面に形成されている薄膜を前記基板に転写して薄膜を形成する薄膜形成方法において、
前記基板と前記シートフィルムとを相互に押し付けることにより実行される前記基板への前記薄膜の転写前における前記薄膜形成室からの単位時間当たりの排気量を、前記基板への前記薄膜の転写中における前記薄膜形成室からの単位時間当たりの排気量よりも少なくなるように調整することで前記薄膜形成室内の圧力を制御することを特徴とする薄膜形成方法。 In the thin film forming method of forming a thin film by transferring the thin film formed on the substrate-side main surface of the sheet film to the substrate by pressing the substrate and the sheet film against each other in the thin film forming chamber,
The amount of exhaust per unit time from the thin film forming chamber before the transfer of the thin film to the substrate, which is performed by pressing the substrate and the sheet film against each other, is determined during the transfer of the thin film to the substrate. A method of forming a thin film, comprising: controlling the pressure in the thin film forming chamber by adjusting the exhaust amount per unit time from the thin film forming chamber to be less. 薄膜形成室内で基板とシートフィルムとを相互に押し付けることにより前記シートフィルムの基板側主面に形成されている薄膜を前記基板に転写して薄膜を形成する薄膜形成方法において、
前記基板と前記シートフィルムとを相互に押し付けることにより実行される前記基板への前記薄膜の転写前における前記薄膜形成室からの単位時間当たりの排気量を制御する電圧を、前記基板への前記薄膜の転写中における前記薄膜形成室からの単位時間当たりの排気量を調整する電圧よりも低くなるように調整することで前記薄膜形成室内の圧力を制御することを特徴とする薄膜形成方法。 In the thin film forming method of forming a thin film by transferring the thin film formed on the substrate-side main surface of the sheet film to the substrate by pressing the substrate and the sheet film against each other in the thin film forming chamber,
A voltage for controlling an exhaust amount per unit time from the thin film forming chamber before the transfer of the thin film to the substrate, which is executed by pressing the substrate and the sheet film against each other, is applied to the thin film to the substrate. A method of forming a thin film, comprising: controlling a pressure in the thin film forming chamber by adjusting the voltage so as to be lower than a voltage for adjusting an exhaust amount per unit time from the thin film forming chamber during transfer of the film.
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